Production Technician - Back End

Brief Description

POSITION SUMMARY:

Our Waco, TX facility manufactures aluminum beverage cans commonly used for soft drinks, beers, energy drinks, teas and non-carbonated beverages. Using state of the art can-making technology, this high speed environment provides rewarding manufacturing opportunities.

The Production Technician for the Back End Area is a multi-skilled role responsible for the operation, quality control, and minor maintenance of the high-speed machinery used in the final critical steps of the aluminum can manufacturing process. This area encompasses Inside Spray Machines (ISM), Necker Machines, Light Testers, and the Palletizer Machine, ensuring compliance with safety, quality, and packaging standards for final distribution.

Essential Job Functions

INSIDE SPRAY MACHINE (ISM) AND COATING

• Setup and Operation: Set up, adjust, and operate multiple high-speed Inside Spray Machines (ISMs) and related oven controls to ensure optimal coating application and curing.
• Coating Management: Monitor and maintain the circulation and delivery of the interior coating material (lacquer), including checking viscosity, temperature, and supply levels.
• Nozzle Setup: Select, install, and adjust spray nozzles, spray guns, and associated fluid handling components to achieve the specified coverage pattern and coating weight.
• Troubleshooting: Quickly diagnose and rectify operational issues such as spray gun malfunctions, material clogs, poor atomization, and conveyor/mandrel timing issues to minimize spoilage and downtime.
• Coating Weight Control: Perform frequent, precise checks of the cured interior lacquer coating weight using specialized laboratory equipment (e.g., electronic coating weight testers, ovens for burnout tests).
• Film Integrity Testing: Execute film integrity tests (e.g., using an enameler or bubble tester) to ensure complete and pinhole-free coverage, preventing direct contact between the beverage and the aluminum.
• Visual Inspection: Conduct continuous visual inspection of cans post-spray and post-oven to identify defects such as skips, thin spray, runs, sags, or poor curing.
• Documentation: Record all quality check data, process adjustments, coating material usage, and downtime events accurately into the plant's quality management system (QMS).
• Preventative Maintenance (PM): Perform routine cleaning and basic preventative maintenance on spray guns, spindles, manifolds, and conveyors to ensure consistent performance.
• Chemical Handling: Safely handle, transfer, and dispose of coating materials and solvents according to established Standard Operating Procedures (SOPs) and safety protocols.
  
  

NECKER AND DIMENSIONAL FORMING

• Necker/Flanger Operation: Set up, operate, and continuously monitor the Necker and Flanger machines, which form the dome and narrow the can opening to accept the lid. Adjust tooling and machine timing to maintain strict dimensional tolerances (e.g., dome profile, flange width, neck diameter).
• Light Tester/Inspection: Operate and monitor electronic Light Testers or other inspection equipment to detect microscopic pinholes, cracks, or structural defects in the cans. Calibrate and adjust sensitivity settings as required to maintain quality standards.
• Process Flow: Manage the continuous flow of cans through the Back End equipment, including conveyors and accumulating tables, to prevent jams, spills, and damage.
• Troubleshooting: Quickly diagnose and resolve operational issues, equipment jams, and minor mechanical or pneumatic failures to minimize downtime.
• In-Process Quality Checks: Perform frequent and detailed dimensional checks on finished cans using precision measuring instruments (e.g., micrometers, calipers, height gauges, seam-checking equipment).
• Defect Identification: Identify and document common Back End defects, such as bad flanges, neck cracks, dome splits, or distorted profiles. Segregate and document all non-conforming product.
• Data Recording: Accurately record production rates, dimensional measurements, and inspection results on shift logs and in the computerized quality management system.
• Minor Adjustments: Perform routine minor tooling and equipment adjustments on the Necker/Flanger machines to correct dimensional drift or address immediate quality issues.
• Cleaning and PM: Execute scheduled cleaning, lubrication, and basic preventative maintenance (PM) tasks on all Back End machinery.
• Support: Work closely with Maintenance Technicians during major machine rebuilds, tooling changes, and complex troubleshooting.
  
  

PALLETIZER AND PACKAGING

• Palletizer Operation: Set up, load materials (pallets, tier sheets, etc.), and operate the Palletizer Machine to stack, sheet, and stabilize finished cans according to customer order specifications and established patterns.
• Integrity Check: Verify pallet stability, accurate can count, correct labeling, and secure staging to ensure packaging integrity for shipment.
• Flow Management: Manage the flow of finished cans into the Palletizer, rapidly clearing jams and addressing minor mechanical issues to maintain production uptime.
• Pallet Inspection: Conduct frequent inspections of finished pallets to verify the stack stability, proper application of tier sheets, correct positioning of top frames, and secure stretch wrapping.
• Count Verification: Monitor can counter systems to ensure accurate pallet counts and reconcile any discrepancies with production records.
• Labeling and Documentation: Generate, apply, and verify all pallet labels, ensuring lot numbers, customer codes, and quantity information are correct for shipping and inventory control.
• Defect Response: Identify and respond immediately to any issues that could compromise the physical integrity of the pallet load (e.g., loose wrapping, shifted layers).
• Troubleshooting: Rapidly diagnose and clear machine jams within the palletizing area and perform minor mechanical and pneumatic adjustments to ensure the automated system operates smoothly.
• Basic Maintenance: Perform routine preventative maintenance (PM) on the palletizer, including cleaning sensors, inspecting drive chains, lubricating moving components, and replacing minor wear parts.
• Collaboration: Work closely with Maintenance Technicians on complex repairs and major system overhauls.
  
  

SAFETY AND HOUSEKEEPING

• Safety Compliance: Strictly adhere to all plant safety rules and procedures, especially regarding conveyors, moving machinery, and lift equipment, utilizing Lockout/Tagout (LOTO) when necessary.
• Work Area: Maintain a clean, organized, and debris-free area around the palletizer and finished goods staging zones.
  
  

GENERAL DUTIES

• Strictly adhere to all safety protocols, including Lockout/Tagout (LOTO), machine guarding, and chemical handling procedures.
• Accurately record production data, quality metrics, and maintenance activities on shift logs and digital systems.
• Maintain exceptional cleanliness and organization in all areas of the Back End line.
  
  

Requirements

EDUCATION & EXPERIENCE:

• Preferred – A Technical degree or the equivalent experience, defined as greater than 4 years of experience in a technical manufacturing continuous improvement environment
• Required – High School Diploma or GED equivalent
• Preferred – 2-3 years of experience operating or maintaining high-speed coating, decorating, or fluid delivery machinery, preferably in can manufacturing or a similar highly automated industrial environment.
  
  

General Skills/Experience

• Mechanical Aptitude: Strong ability to operate and adjust complex machinery with a focus on high precision.
• Precision Measurement: Proficiency in using precision measuring instruments (micrometers, calipers, specialized gauges).
• Detail Orientation: Exceptional focus on detail for identifying subtle structural, dimensional, and coating defects.
• Automation Familiarity: Basic understanding of automated packaging systems (Palletizers) and electronic inspection equipment.
• Must be willing and able to work rotating shifts, including nights, weekends, and overtime, as required.
• Ability to work with employees from many different cultures and backgrounds
• Preference will be given to qualified local candidates
  
  

Software/Computer Skills & Experience

• General knowledge of basic hardware and software and uses of a variety of different computer operating systems such as Microsoft Office Work, Excel, Outlook, Google Workspace, and web-site software
  
  

Disclaimer

The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties, and skills required of personnel so classified. Management maintains the right to assign or reassign duties and responsibilities to this job at any time.

Environmental & Physical Factors

The physical demands and work environment described below represent the activities and surroundings of the position(s). Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Works primarily in a warehouse/manufacturing facility. Daily contact with other departmental personnel. Occasionally works in all weather conditions, extreme temperatures, around chemicals and chemical fumes/emissions, dusty & clean environments. Frequently works with electrical and mechanical hazards. When working with surplus and scrap materials, will frequently be required to work outside and/or in an unaired conditioned warehouse. Continuous use of vision, hearing and speech. Frequent sitting, standing, walking and occasional bending. Will lift, carry, pull / push, and reach for supplies and on occasion lifting (up to 50 lbs.) while performing various aspects of the job; Will need to climb stairs, climb ladders, lift and move objects, requires manual dexterity and repetitive use of keyboard/computer devices/power tools/machining equipment; Wear safety equipment, such as earplugs, goggles, and steel-toed shoes.

Hours / Special Conditions

12 hour rotating shifts 4 days on and 4 days off; Rotating shifts requires working night shifts; Present to fulfill job duties & meet operational demands/support; Schedule may vary depending on plant operational needs thus flexibility is required which may include long days, evenings, weekends, holidays and overtime; Regular and predictable attendance is an essential function of this position.

Envases Commerce, LLC is an Equal Opportunity Employer.